A method of manufacturing a liquid container of plastic coated boxboard, laminated cardboard or the like having a straw therein is disclosed. A method for attaching a holder/straw assembly to a carton in a continuous form, fill and seal process including the following steps: unrolling a rolled sheet material being comprised of a plurality of carton sections, each carton section having a hole formed therein; sealingly attaching the holder/straw assembly to the sheet material over said hole; attaching a strip to the holder/straw assembly; forming the sheet into a columnar sleeve; sealing a longitudinal seal along the columnar sleeve; adding the beverage into the sealed columnar sleeve; forming a top and bottom transverse seal across the columnar sleeve and through the beverage; cutting each carton from the columnar sleeve; and forming a parallelepipedic carton having a drinking straw therein.
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18. A process for attaching a holder and straw assembly to a carton in a sleeve form, fill and seal process comprising the steps of;
receiving a flattened sleeve; expanding the sleeve having a hole formed therein; sealing one end of the sleeve; sealingly attaching the holder and straw assembly to the sleeve over said hole; attaching a strip to the holder and straw assembly; adding the beverage into the sealed columnar sleeve; sealing the other end of the sleeve; and forming a carton having a drinking straw therein extending from one end thereof.
1. A process for attaching a holder and straw assembly including a straw portion to a carton in a continuous form, fill and seal process comprising the steps of:
unrolling a rolled sheet material being comprised of a plurality of carton sections, each carton section having a hole formed therein; sealingly attaching the holder and straw assembly to the sheet material over said hole; such that the straw portion extends inside the sleeve attaching a strip to the holder and straw assembly; forming the sheet into a columnar sleeve; sealing a longitudinal seal along the columnar sleeve; adding the beverage into the sealed columnar sleeve; forming a top and bottom transverse seal across the columnar sleeve and through the beverage; cutting each carton from the columnar sleeve; and forming a parallelepipedic carton having a drinking straw therein.
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This patent application is a continuation of Patent Cooperation Treaty application PCT/CA99/00400 which designates the United States and was filed May 13, 1999 and entitled STOPPERS FOR INDIVIDUAL BEVERAGE CONTAINERS and continuation of U.S. application Ser. No. 09/401,314 filed Sep. 23, 1999 and entitled INDIVIDUAL BEVERAGE CARTON WITH A STRAW THEREIN AND A METHOD OF MANUFACTURE.
The present invention relates generally to the provision of a drinking straw with an individual beverage carton and in particular to the provision of a drinking straw on the inside of an individual beverage carton and a method of manufacture thereof.
Packaged individual beverage cartons of plastic coated paper board sheet material folded into a generally parallelepipedic shape have been made available to consumers for many years and are often referred to as "juice boxes".
Various arrangements have been proposed to provide a straw with an individual beverage carton. In general, a cylindrical plastic drinking straw is packaged in a separate sealed plastic envelope and attached usually with an adhesive to the outside of the beverage carton. The straw may be straight or it may have an accordion type bend therein. In use, the consumer is required to remove the drinking straw from its envelope and insert it through the packaging of the container at a predetermined place usually on the top of the container, the straw then being ready to allow consumption of the beverage from the container. As the drinking straw once inserted into the beverage carton makes consumption of the beverage possible, conversely consumption of the beverage from the container without the use of the drinking straw is problematic and objectionable.
One disadvantage of the assembly as described above is that the straw has to be inserted into the beverage carton prior to use. In order to insert the drinking straw into the beverage carton the consumer has to pierce a portion of the carton. Typically there is a preferred point of entry or insertion point that can be identified by a round hole in the carton (but not in the foil liner) on its top. However, the consumer has to puncture the foil liner so that the straw has access to the liquid therein. The foil liner can withstand relatively high pressures such that the carton will not readily leak at the insertion point. As the act of inserting the drinking straw through the packaging material at the predetermined place requires considerable force, the beverage carton also needs to be simultaneously held soundly. This holding soundly often means squeezing the beverage carton and therefore there exists the risk that beverage will rapidly vacate the beverage carton either up the straw or around the straw at the insertion point upon insertion, thereby causing the beverage to be spilled. The consumer is at risk of spilling the beverage on themselves or someone or something at hand. This risk is further increased by the fact that a high percentage of these beverages are consumed by children, individuals that may lack some degree of hand coordination or who may consider the spraying of liquid desirable. This, of course, is not desirable or a game to the parent.
Another disadvantage of the current system of attaching the drinking straw and protective plastic envelope to the outside of the beverage carton is that the protective plastic envelope will often merely be discarded as litter. Commonly, removal of the existing drinking straw currently provided with the beverage carton of the previously mentioned type also requires removal of the straw's protective plastic envelope from the outside of the beverage carton to which it is attached when received by the consumer. This leaves the consumer in the possession of the now empty plastic envelope and due to the small size of the plastic envelope and its low weight the consumer is often tempted to discard the plastic envelope as litter. As the empty envelope is manufactured of plastic, the envelope will exist in the environment for some time before breaking down and due to its small size and low weight is not likely to be picked up as garbage.
A still further disadvantage of the current system of attaching the drinking straw and protective plastic envelope to the outside of the beverage carton is that the straw will obscure the writing and art work on one side of the carton. In addition, as the plastic envelope containing the drinking straw is attached to the outside of the beverage carton there exists considerable risk that the plastic envelope and drinking straw will be inadvertently removed from the outside of the beverage carton and lost, placing the consumer in a compromised position when the time comes for the consumption of the beverage from the container.
Some arrangements have been proposed wherein a straw is provided in an individual beverage carton. For example U.S. Pat. No. 5,188,283 issued to Gu on Feb. 23, 1993, shows a straw in four different types of containers. In the parallelepipedic shaped container there is provided a hole in the container through which the straw is positioned. A groove is provided on the inside of the top tuck flap that is in registration with a top portion of the straw when the tuck flap is sealed to the container. Another example of providing a straw in a parallelepipedic shaped container is shown in U.S. Pat. No. 5,482,202 issued to Wen on Jan. 9, 1996. This container has a straw that is attached in the seams of the container and in at least one embodiment the straw extends from a top side edge to the opposed bottom side edge. An alternate approach is shown in U.S. Pat. No. 5,1116,105 issued to Hong on May 26, 1992. This container has a short straw or pipette attached to the underside of the top tuck flap which is the extension of the top seam. The short straw is less than half the width of the container and is used more as a pouring spout than a drinking straw. The short straw is on the outside of the container and has to be inserted through the side wall of the container.
Each of these examples of a straw provided in an individual beverage container suffers from disadvantages. The Gu container would be difficult to manufacture. Firstly, the groove would be difficult to form in the top tuck flap. Secondly the top tuck flap with the groove therein would be difficult to seal once the container is filled with liquid. Thirdly the straw, hole and groove arrangement would not be adaptable to the continuous form, fill and seal process that is preferred for the manufacture of parallelepipedic shaped containers. The Wen container similarly would not be adaptable to the continuous form, fill and seal process since a good seal in a seam having a straw therein would be difficult to achieve. Further, a straw in the seam might lead to leakage through the straw. The Hong container provides a pour spout but does not eliminate the necessity of the consumer having to push the short straw or pipette into the container with all of the disadvantages associated therewith and it also has the disadvantage described above that the straw can be easily lost.
As the preferred method of manufacture of existing parallelepipedic plastic coated paper board material beverage cartons, involves a continuous form, fill and seal process, there are limited opportunities for the application of a drinking straw on the inside of the carton, so that the drinking straw may be inside the beverage carton at the time of purchase of the beverage by the consumer.
In general, the form, fill and seal process is composed of the steps of unrolling a preprinted and precreased plastic laminated paper board sheet; forming the sheet into a columnar sleeve; sealing a longitudinal seal along the columnar sleeve; adding the beverage into the sealed columnar sleeve; forming a transverse seal across the columnar sleeve and through the beverage; cutting the package from the columnar sleeve and forming a parallelepipedic carton with folded and fixed tabs.
Accordingly it would be advantageous to process for attaching a drinking straw to an individual beverage carton such that the drinking straw is on the inside of the beverage carton.
In one aspect of the invention a method of manufacturing a liquid container of plastic coated boxboard, laminated cardboard or the like having a straw therein is disclosed. The method for attaching a holder/straw assembly to a carton in a continuous form, fill and seal process including the following steps: unrolling a rolled sheet material being comprised of a plurality of carton sections, each carton section having a hole formed therein; sealingly attaching the holder/straw assembly to the sheet material over said hole; attaching a strip to the holder/straw assembly; forming the sheet into a columnar sleeve; sealing a longitudinal seal along the columnar sleeve; adding the beverage into the sealed columnar sleeve; forming a top and bottom transverse seal across the columnar sleeve and through the beverage; cutting individual cartons from the columnar sleeve; and forming a parallelepipedic carton having a drinking straw therein.
In another aspect of the invention a sleeve form, fill and seal process of manufacturing beverage cartons having a straw/holder assembly attached thereto so as to provide a straw therein is disclosed. The method includes the following A process for attaching a holder/straw assembly to a carton in a sleeve form, fill and seal process comprising the steps of: receiving a flattened sleeve; expanding the sleeve having a hole formed therein; sealing one end of the sleeve; sealingly attaching the holder/straw assembly to the sleeve over said hole; attaching a strip to the holder/straw assembly; adding the beverage into the sealed columnar sleeve; sealing the other end of the sleeve; and forming a carton having a drinking straw therein extending from one end thereof.
Further features of the invention will be described or will become apparent in the course of the following detailed description.
The invention will now be described by way of example only, with reference to the accompanying drawings, in which:
Referring to
The holder 34 for the straw 32 is shown in more detail in
A vent hole 42 is provided in trough 36 to allow atmospheric pressure to gain access into the beverage carton 30 to facilitate consumption of the beverage with the straw 32 by the consumer. Alternatively, the hole 42 need not be provided if there is sufficient clearance between the straw 32 and the aperture 38 of the holder 34 to allow atmospheric pressure to enter the internal volume 44 of the beverage carton 30. This allows the consumer to suck the beverage up through the straw 32 without creating a vacuum inside the beverage container 30.
A drinking straw 32 as shown in
Referring to
The holder 34, straw 32 and strip 52 can be preassembled as an assembly 56 shown in FIG. 5. Referring to
Alternatively referring to
Both sides of strip 52 and tab 54 may be used for advertising or promotional material or the like.
Preferably, the unsealed margin 61 of the packaging material 48 at the oblong hole 60 is not exposed to the liquid contents of the finished carton 30. Accordingly, as shown in
Preferably the finished beverage carton 30, as shown in
As a further application of the holder 34, straw 32 and strip 52,
As an additional embodiment of the holder and strip, a resealable adaptation is illustrated in
Referring to
Assembly of the holder assembly 100 including inner portion 102, straw 32 and strip 52 in the outer portion 104 could occur either before or after the outer portion 104 is attached to the carton 68. Inner portion 102 could be positioned in any rotational attitude, either with the trough 112 being horizontal, as in
Referring to
Referring to
Referring to
Referring to
It will be appreciated by those skilled in the art that liquid container, holder and straw assembly of the present invention have a number of advantages over the prior art. For example since the straw is placed on the inside of the container prior to the container being purchased by a consumer there will be a reduced likelihood of spillage since the user need not pierce the container with the straw. A further advantage is that the straw will not obscure any printed material that is on the outside of the container. A further advantage is that by providing the straw on the inside of the container there is no longer a need for a protective plastic envelope. The liquid container, holder and straw assembly of the present invention provides an aperture formed in the holder and a straw that fits snugly therein, thereby providing access to the liquid only through the straw. This configuration minimizes the likelihood of spillage during use.
Referring to
The sheet packaging material 48 is taken from the reel 72, raised and brought into a vertical orientation where the sheet is wrapped into a continuous columnar sleeve 74 and sealed at a longitudinal seam 76 by a heated sealing device 78. Beverage is added into the columnar sleeve 74 below the sealing device 78 via a pipe 80 that enters the columnar sleeve 74 prior to the formation of the columnar sleeve 74.
At intervals that establish individual cartons of beverage, a transverse seam 82 is formed across the columnar sleeve 74 and through the beverage by sealing jaws 96, The lower portion of the columnar sleeve 74 is roughly formed into an individual carton 84 by forming dies 86 and is then cut from the columnar sleeve 74 by cutting jaws 98. The top and bottom flaps of the cut off cartons 88 are folded, the top flaps 90 are secured to the sides of the carton and the bottom flaps 92 are secured to the bottom of the carton to form the finished carton 31 as described above. It will be appreciated by those skilled in the art that only the basic steps of the form, fill and seal process are shown. For example other pairs of forming dies are required to transform the cut off carton 88 as cut from the columnar sleeve 74, from its cushion shape to the parallelepipedic carton 31 shape.
Referring to
A guide 94 which is generally an elongate "L"-shaped guide and which is generally "U"-shaped in cross section is illustrated in
At a point below the formation of the longitudinal seam 76 the guide 94 is terminated and the straw 32 is allowed to lean against the opposite wall of the columnar sleeve 74 as illustrated in FIG. 15. As seen in
As the columnar sleeve 74 is progressively advanced downwardly, beverage is supplied to the inside of the columnar sleeve 74 via beverage pipe 80, forming dies 86 roughly form the individual cartons 84, sealing jaws 96 form a transverse seal 82 across the columnar sleeve 74 and through the beverage and cutting jaws 98 cut the sealed individual carton 84 from the columnar sleeve 74.
The top flaps 90 and bottom flaps 92 resulting from the forming and cutting steps are folded and attached to the sides and bottom respectively of the beverage carton, to produce the finished beverage carton 30, also shown in FIG. 1.
The finished beverage carton 30 is illustrated in
It will be appreciated by those skilled in the art that there are a number of variations in the steps that may be used to attach the assembly 56 to the sheet packaging material 48. For example the assembly 56 may be attached to the outside of the sheet packaging material 48 (that is the outside of the carton when it is formed) rather than the inside the seal 52 may be attached separately or at the same time as the rest of the assembly 56; the hole 60 may be cut at the same time as the assembly 56 is attached, just prior to attaching the assembly 56 or prior to the sheet packaging material 48 being wound onto reel 72. Similarly the attachment of the assembly 56 can also be adapted to a sleeve form, fill and seal process and similar variations thereof can also be contemplated.
Some of variations in the details of the step of attaching the assembly 56 in the continuous form, fill and seal process will now be discussed with reference to
As shown in
An application of assembly 172 to the form, fill and seal process of manufacturing a filled beverage carton is shown in section in
As an alternative to the assembly process shown in
An application of assembly 56 to the form, fill and seal process of manufacturing a filled beverage carton is shown in section in
A variation to the assembly attaching process shown in
Another variation is shown in
As discussed, the application of assembly 172 and seal 52 can be applied to the production of a filled beverage carton by means of the sleeve form, fill and seal process shown in FIG. 37. During this process a carton sleeve that has a longitudinal seal already formed and that is folded into a flattened parallelogram shape 178, is taken and raised into a sleeve form 180, slid onto a mandrel 182, has its top end closed, sealed and resulting tabs folded and secured to the sides of the carton 184. The carton then has a hole 60 cut in the top of the carton and the waste portion 174 is then removed. Assembly 172 and seal 52 are then attached on either side of hole 60. Assembly 172 may be applied to the inside of the carton and seal 52 may be applied to the outside of the carton as best seen in FIG. 37. As with the form, fill and seal process shown in
A number of variations of the sleeve form, fill and seal process are shown in
The manufacture of gable top cartons can also be adapted to include a straw assembly. Referring to
It will be appreciated by those skilled in the art that the elements of the assembly 56 shown here as being attached in one step could be attached separately. That is the holder 34 could be attached to sheet material 48 and then the straw 32 inserted therein and then sealing strip 52 attached to the holder 34 or the sheet material 48 and holder 34. Further, it will be appreciated by those skilled in the art that any of the above processes could be adapted such that the hole 60 is cut into the sheet packaging material 48 prior to it being rolled onto real 72 or prior to the formation of flattened parallelogram shapes 178, 192. In addition the hole 60 could be sealed as shown in
It will be appreciated that the above description related to the invention by way of example only. Many variations on the invention will be obvious to those skilled in the art and such obvious variations are within the scope of the invention as described herein whether or not expressly described.
Haughton, Keith Louis, Haughton, Glenn Wallace, Hillar, Peter Christopher Michael
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Jun 04 2001 | HAUGHTON, KEITH LOUIS | BEVTEK INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 011943 | /0949 | |
Jun 04 2001 | HAUGHTON, GLENN WALLACE | BEVTEK INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 011943 | /0949 | |
Jun 04 2001 | HILLAR, PETER CHRISTOPHER MICHAEL | BEVTEK INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 011943 | /0949 |
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